HSE-SAF-PRO-00-0015 · HSE-SAF-PRO-00-0015 Page 3 of 23 4. PROCEDURES 4.1. General i. A completed...

SAFETY

HSE-SAF-PRO-00-0015

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HOT TAP/STOPPLE AND HOT TAP/STOPPLE WELDING PROCEDURE

26-Mar-2018

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HSE-SAF-PRO-00-0015 Page 1 of 23

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................ 2

2. SCOPE & PURPOSE ..................................................................................................... 2

3. DEFINITIONS ................................................................................................................. 2

4. PROCEDURES .............................................................................................................. 3

5. RESPONSIBILITIES .................................................................................................... 11

6. REFERENCES ............................................................................................................. 15

7. ATTACHMENTS .......................................................................................................... 15

8. APPENDICES .............................................................................................................. 15

9. REVISION HISTORY.................................................................................................... 23

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

4 26-Mar-18

Periodic Revision

Added mock welding general safety requirement (sec. 4.3.vi-viii)

Added P&TA Manager & Technical Manager to sign the Hot Tap/Stopple Request Form (sec. 4.1.1.ii-iii)

Added notes on ‘welding on in-service piping’ (sec. 4.6)

Added requirement of ‘Specific Limitations for Hot Tapping’ (sec. 4.7.(i,v,vi))

Added references in section 6.3 - 6.5

Muhammad F Khan

Arantelo D Abreu/

Hesham Y El Zeini/

Muhammad A Naveed/ Naif Y Al-Motawa/

Abdul W Sheikh Atef Khalafalla

Saravanan Velayutham/ Karthikeyan

Ponnuswamy/

Ryan L Price Roehl

Bartolome/ Choondassery

Umesh/ Rahamathulla

h Syed/ Syed N Shah Abdulla S Al-

Khulaifi Abdulaziz Y Al-Motawa/ Dirk Perrin/

Abdulla S Al-Zoubi/

Next Scheduled Periodic Review: March/2023

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1. INTRODUCTION

It is recognized that all ‘Hot Tapping/Stoppling’ and ‘Hot Tap/Stopple Welding’ are performed under less than ideal conditions, so it will be performed only when absolutely necessary and only if it can be performed safely. This procedure establishes a clear set of instructions to be followed when planning and performing Hot Tap and Stopple installations at Q-Chem and RLOC facilities.

2. SCOPE & PURPOSE

The purpose of this Hot Tap/Stopple and Hot Tap/Stopple Welding Procedure is to provide guidelines which, when followed, will reduce the possibility of injury to personnel and damage to plant equipment.

3. DEFINITIONS

DSR – Designated Site Representative

GTAW – Gas Tungsten Arc Welding.

Hot Tap - The technique of attaching a mechanical or welded branch fitting to piping or equipment in service, and creating an opening in that piping or equipment by drilling or cutting a portion of the piping or equipment within the attached fitting, while the pipeline or vessel is operating under pressure or at less than atmospheric pressure, or out of service piping/vessels which cannot be cleared to 0% LEL.

Hot Tap Welding - Welding that is required to attach a branch connection fitting, Hot Tap/ Stopple fitting, to an operating pipeline, main, storage tank, pressure vessel, and connecting branch piping while the pipeline or vessel is operating under pressure or to an out of service pipeline/vessel which cannot be cleared to 0% LEL.

LEL - Lower Explosive Limit - The minimum concentration of a vapor in the air (or other oxidant) below which propagation of flame does not occur on contact with an ignition source. The lower explosive limit is usually expressed in terms of volume percentage of the vapor in air. Sometimes called Lower Flammable Limit (LFL).

Mill Test Report - Certifies a material’s chemical and physical properties and states a product made of metal is in compliance with an international standards organization (such as ANSI, ASME, etc.) specific standards.

Modification - The installation of a Hot Tap/Stopple fitting may be a modification and shall follow the established guidelines for the Management of Change.

SAP- Systems, Applications, and Products

SDS - Safety Data Sheet - provides workers and emergency personnel with procedures for handling or working with that substances in a safe manner, and includes information such as physical data (melting point, boiling point, flash point, etc.), toxicity, health effects, first aid, reactivity and storage.

Stoppling - The practice of plugging an operating pipe system in order to prevent flow.

TWR - Technical Work request.

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4. PROCEDURES

4.1. General

i. A completed work package shall be required prior to initiation of mechanical work and shall be available at the job site. The work package is created by the Job Planner or Project Engineer and consists of the following forms and permits:

a) Completed ‘Hot Tap/Stopple Request’ and all of the information submitted when asking for approval

b) Marked up P&ID

c) SAP Request or Contract

d) Mill Test Reports

e) SDSs related to the job. (Examples: sealing compound, process fluids)

f) Permit(s) to Work

g) Hot Tap/Stopple Sign-off Form

h) Hot Tap/Stopple Measurement Form

i) JSA

j) Equipment certification

k) Maintenance work order

ii. These forms and permits shall be filled out and proper signatures obtained prior to initiation of mechanical work.

4.1.1. An approved Hot Tap/Stopple Request Form

Form shall have complete details as to the scope of work; pipe or vessel contents or possible contents along with normal operating pressures and temperatures; pressures and temperatures that will be maintained during the attachment and Hot Tap/Stopple process; if applicable, flow rates; original design specifications along with nameplate data, or any other pertinent information.

i. The following information shall accompany the Hot Tap/Stopple Request Form

a) Statement of the compatibility of the pipe or vessel content with welding and existing metal thickness readings

b) Engineering drawings

c) Support documents for the Management of Change (MOC)

d) External pressure calculation

e) Calculated flowing media velocity while welding

f) Type and material description of the attachment fitting

g) Welding procedure

h) Welding process

i) Type of valve

j) Type of pressure test

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k) Attached fitting and valve pressure test certificate.

ii. When Hot Tapping/Stoppling a pipe or vessel containing hydrocarbons or there is a deviation from the standard Hot Tap/Stopple Procedures, the ‘Hot Tap/Stopple Request Form’ shall be signed by the Project Engineer, the Head of Project Engineering, The Production Area Superintendent, Manager, Projects and Turnaround, Technical Manager, Production Manager, the Safety Manager/HSE Superintendent and the Plant Manager /Deputy Plant Manager or their designees.

iii. When hot tapping/Stoppling a pipe or vessel not containing hydrocarbons, the Hot Tap/Stopple Request Form shall be signed by the Project Engineer, Manager, Projects and Turnaround, Technical Manager, Head of Project Engineering, Production Area Superintendent, the Production Manager/Deputy Plant Manager and the Safety Manager/HSE Superintendent or their designees.

iv. Marked Up P&ID

v. Execute MOC with necessary approvals.

vi. SAP/TWR: A SAP/TWR is initiated by the Project Engineer and is submitted along with other necessary documents to the Area Mechanical Planner.

vii. Mill Test Report: This report is to be received by the Area Mechanical Planner/Engineering Superintendent from the vendor who supplies purchased materials for new materials and from plant records for existing piping or vessels.

viii. SDS: Safety Data Sheets identify the physical and chemical characteristics of materials being utilized, as well as potential hazards posed by these materials. SDSs are to be provided by the Project Engineer to the Area Mechanical Planner.

ix. Permit to Work: Prior to issuance of a permit to work the proper forms shall be properly completed as part of the work package. The permit shall state all the precautions necessary for a safe work environment. Reference Section B (Permit to Work, HSE-SAF-PRO-00-0006.

x. Hot Tap/Stopple Work Sign-off List: Establishes hold points at specific times during work. Each step shall be signed by the individual responsible parties prior to proceeding to the next job step (this is not to say they must be signed individually, they may be signed in conjunction).

xi. Hot Tap/Stopple Measurement Form: Hot Tap Operator is required to make the necessary measurements specific to the hot tap to ensure proper distance between machine parts and flange faces are met and drill length is correct.

4.2. Job Analysis/Risk Assessment

i. The first step in the hot tapping work process is establishing what needs to be accomplished, how the associated work is to be done, and whether hot tapping is appropriate. The general review process is shown in Figure 1 of API Recommended Practice 2201. Since hot tapping involves hot work on equipment in service, a work scope analysis shall be performed to determine if alternates to hot tapping exist within reasonable engineering and economic bounds, and whether hot tapping is appropriate. If, after review, hot tapping is indeed required, the following approach conforms to good practice and regulatory requirements:

a) Since the work cannot be moved, a review shall determine whether fire hazards in the vicinity can be moved to a safe place.

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b) All precautions used for hot work shall be followed. Since hot tapping work cannot be done except by performing hot work in place, the work area and each activity shall be closely analyzed for hazards, such as. SDSs relevant to the materials involved. (Refer API 2201 for more details.)

ii. This shall minimize the risk that hot work may provide as a source of personnel exposure or ignition hazards which could lead to a fire or explosion. The consequences of each hazard shall be carefully weighed along with unexpected conditions that might occur during hot work.

iii. The example flow chart in Figure 2 (Appendix – III) shows some of the thought required in making the decision that use of hot tapping is appropriate. OSHA 29 CFR 1910.147 “Control of Hazardous Energy” (Lockout/Tagout) provides a specific exemption for performing hot tapping, with several criteria which must be met to satisfy that this is both needed and safe. These criteria are:

a) Maintaining continuity of the service being hot tapped is essential;

b) Shutdown of the system is impractical or results in unacceptable levels of additional risk;

c) Documented procedures for managing the risks of hot tapping are followed;

d) Special hot tap equipment is used which will provide proven effective protection for employees.

iv. As indicated in Figure 2, if all four of these criteria cannot be met then hot tapping shall not be done and the work must be performed in conformance with the requirements of the HSE-SAF-PRO-00-0004, Lockout, Tagout and Try (LT&T) Procedure.

v. The hazard evaluation and risk assessment should be carried out in accordance with Management of Change/Pre-Start up Safety Review (MOC) procedure (QC-PSM-PRO-00-0003). Contingency plans shall be put into place for firefighting, personnel evacuation, and/or alternate methods (such as changes in plant operations) to finish the hot work without incident. Appendix D of API Recommended Practice 2201 provides an example of a hot tap emergency action contingency plan.

4.3. General Safety Requirements for Hot Tapping/Stoppling and Hot Tap/Stopple Welding

i. Out of service piping or vessels shall have a LEL of 0% before being tapped or welded upon; otherwise, the Hot Tap/Stopple and Hot Tap/Stopple Welding Procedures apply.

ii. Hot Tap/Stopple work shall stop when the proper operating conditions cease to exist or at any time to continue the work would be considered unsafe.

iii. All Hot Tapping/Stoppling and Hot Tap/Stopple Welding shall be performed during normal day light working hours.

iv. Area around Hot Tapping/Stoppling or Hot Tap/Stopple Welding is to be roped off with barrier tape in order to restrict personnel exposure in the event that unforeseen events occur.

v. Hot Tap/Stopple personnel must show proof of qualification/experience for performing work. All Hot Tap/Stopple Welding shall be performed to compatible and qualified welding procedures by qualified welders.

vi. Mock welding test shall be conducted by the contractor and witnessed by ERG to demonstrate the adequacy of welding procedure. The mock test shall be documented and attached with the hot tap approval form.

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vii. All personnel involved in the execution of Hot Tapping/Stoppling process shall be familiar with the appropriate information in the applicable Safety Data Sheets.

viii. ‘Hot Tapping/Stoppling or Hot Tap/Stopple Welding’ above grade:

a) When Hot Tapping/Stoppling or Hot Tap/Stopple Welding is to perform above grade-approved scaffolding shall be erected when needed.

b) Safe egress must be available and need to be discussed in JSA.

c) Adequate ventilation shall be maintained as per Fire Box Standard

d) A dry chemical fire extinguisher and/or a charged fire hose shall be readily available at all Hot Tap/Stopple and Hot Tap/Stopple Welding sites.

e) Static and dynamic loads on scaffolding to be analysed in case if any hot tap/ stopple equipment is going to be placed on scaffold structure.

f) Securing the pipe (that required hot tap) shall be secured from both sides to cater the additional loads on the new installations.

ix. Inspection of the area where attachment is to be made shall include an area out to 10 centimetres minimum past the welding zone of the branch (for hot taps without reinforcing pad) or the welding zone of the reinforcing pad (for hot taps with reinforcing pad). The inspection shall be performed in such a manner as to identify any and all defects including laminations that may be present within the base material and to determine the actual minimum wall thickness.

x. All material to be utilized for Hot Tap/Stopple fitting shall be accompanied with Mill Test Reports.

xi. To minimize the possibility of burn-through, Hot Tap/Stopple Welding on carbon steel shall be performed using a 3/32” (2.4mm) or smaller dia low hydrogen electrode with minimum heat input for the first weld pass. Subsequent passes shall be made with 1/8” (3.2mm) dia or smaller if the wall thickness does not exceed 12.7mm (½ inch). For wall thickness of 12.7 millimetres or greater, where burn through is not a primary concern, large diameter electrodes may be used. It is permissible to use a GTAW welding process for the root pass when using a suitably qualified welding procedure.

xii. During all Hot Tap/Stopple Welding, the heat input to the electrodes shall be as low as practical in order to minimize the inside wall temperature. However, very low heat inputs can increase the risk of cracking in high carbon equivalent materials.

xiii. Hot Tap fittings are to be at least one nominal line size smaller than the line tapped into except when using a full encirclement fitting.

xiv. Hot Taps to make full size branch connections are not allowed.

xv. For Hot Tapping on austenitic stainless steel lines/equipment, only “L” grades (304L, 316L, etc.) or stabilized (321 or 347) may hot tapped. Caution is advised when welding on stainless steels since the environments may contain chlorides. Stopple fitting will be full encirclement fittings.

xvi. All Hot Tap/Stopple fittings will be at least the nominal thickness of the material being Hot Tapped or Stoppled.

xvii. No piping or vessel shall have Hot Tap/Stopple Welding performed in an area that is severely pitted, cracked, blistered, or has a lamination present.

xviii. All valves that may impact the volumetric flow, shall be car sealed open and tagged with the “Do not Operate or Use” tag for the duration of Hot Tap/Stopple Welding.

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4.4. General Limitations on Hot Tappling/Stoppling and Hot Tap/Stopple Welding on Piping and Vessels Due to Content

Some materials decompose violently at elevated temperatures, therefore, piping or vessels that contain the following contents SHALL NOT have the Hot Tap/Stopple Welding performed on them without an approved deviation to the Hot Tap/Stopple procedure.

i. Acetylene, Amine, Acids, Butadiene, Caustics, Chlorine, Chloride, Compressed Air, Ethylene, Ethylene Oxide, Hydrogen, Oxygen, Peroxide, Propylene, Styrene, Combustible Mixtures, any Heat Reactive Material, and other unsaturated hydrocarbons not listed.

ii. Specialty Chemical Lines: There is not enough empirical data available to warrant classifying these pipe lines or vessels as safe to weld upon. Examples of these lines would be catalyst lines and lines containing pyrophoric material.

iii. Mixtures containing hydrogen operating above the Nelson curve limits because of the possibility of hydrogen embrittlement of the steel.

iv. Vapour/air or vapour/oxygen mixtures near or within their flammable explosive range.

v. Compressed air systems, unless known to be free of flammables and combustibles such as lubricating oil residues.

vi. Temperature-sensitive, chemically reactive materials (for example, peroxides, chlorine, or other chemicals which might violently decompose or become hazardous from the heat of welding).

4.5. Hot Tap Location

i. The hot-tap branch shall be installed at 90 degrees to the axis of the run-pipe.

ii. On horizontal surfaces tapping is best performed in the vertically downward position.

iii. The greater the deviation from this position, the more difficult it becomes to support the hot-tap machine and to fit and weld the nozzle. Tapping in positions below the 90° and 270° positions, where the machine is pointed upwards, shall be avoided because of the possibility of debris collecting in the nozzle attachment and possibly preventing closure of the isolating valve.

iv. The separation of the attachment fillet welds from existing circumferential welds should be at least one run pipe outside diameter and shall not be less than 150 mm.

v. Interference with the longitudinal weld seam of the run-pipe shall be avoided wherever possible. If the run-pipe is of the spiral-weld type, the branch shall be located so that the spiral weld either cuts the area to be removed by the hot-tap perforation into two equal parts or avoids it completely.

vi. A reduced branch fitting or reinforced set-on branch shall not be welded on top of a longitudinal or spiral weld seam. A distance (measured from the toe of the welds) of at least seven times the run-pipe wall thickness or 75 mm, whichever is the greater, shall be maintained between the connection to be installed and an existing connection or the longitudinal or spiral weld.

vii. The chosen location on the run-pipe shall be checked and verified as suitable for the hot-tap connection, taking into account at least the following factors:

a) Diameter and ovality;

b) Pipe wall thickness;

c) Internal and/or external corrosion;

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d) Defects in the pipe wall (e.g. laminations);

e) Soundness of adjacent welds;

f) Internal deposits.

4.6. General Limitations for Hot Tapping/Stoppling and Hot Tap/Stopple Welding on Piping and Vessels

The following limitations shall apply to all piping or vessels that are subject to have Hot Tap/ Stopple Welding or Hot Tapping/Stoppling performed on them:

i. No vessel or piping, which is cladded from inside or has an inner lining, shall have Hot Tap/Stopple Welding or Hot Tapping/Stoppling performed on it.

ii. The pressure and temperature shall be reduced as much as the system operation will allow. However, no pipe or vessel containing hydrocarbon shall be subject to Hot Tap/Stopple Welding if it has an internal pressure greater than 10.5 Kg/cm2, or if it is operating at less than atmospheric pressure or more than 50% of its maximum allowable working pressure. No pipeline or vessel material shall be subject to Hot Tap/Stopple Welding if it is known to contain a 0.40 percent or higher carbon content.

iii. No Hot Tap/Stopple Welding will be performed on any material that will require post weld heat treating/on post weld heat treated piping and equipment.

iv. Piping or vessels that are to have Hot Tap/Stopple Welding performed on it shall be at a minimum of 15ºC.

v. Piping or vessels that are to have Hot Tap/Stopple Welding performed on it shall be clean and dry.

vi. No Hot Tap/Stopple Welding shall be performed within 0.5 meters of a flange or threaded connection unless determined by an engineering review to be acceptable.

vii. No Hot Tap/Stopple Welding will be performed within 75 mm of a welded seam unless determined by an engineering review to be acceptable.

viii. In certain cases, such as a flare line, there may be insufficient or interrupted flow that may result in a flammable mixture during the welding operation. It may be necessary to continually purge or flood the line with steam, inert gas or hydrocarbon gas to prevent the formation of pockets of flammable mixtures.

ix. No Hot Tap/Stopple Welding will be performed immediately upstream of rotating equipment, (including lube/seal oil systems) flow meter elements, control valves, pressure relief valves etc. unless suitable filters or traps are in place to prevent damage by cuttings.

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NOTE 1

The two primary concerns when welding on in-service piping and equipment are burn-through and cracking.

Burn-through will occur if the un-melted area beneath the weld pool can no longer contain the pressure within the pipe or equipment.

Weld cracking results when fast weld cooling rates produce a hard, crack-susceptible weld microstructure.

Fast cooling rates can be caused by flowing contents inside the piping and equipment which removes heat quickly.

Consideration should be given to evaluating heat transfer during welding to determine the heat input and related welding variables in order to prevent overheating and burn through of the in-service piping or equipment.

Also, consideration should be given to evaluating the expected cooling rate of the weld to determine the heat inputs required to produce welds (and heat affected zones) which are free of cracking.”

4.7. Specific Limitations for Hot Tapping/Stoppling and Hot Tap/Stopple Welding on Piping

The following limitations shall apply to all piping subject to have Hot Tap/Stopple Welding performed on it:

i. Minimum thickness requirement against internal and external pressure that allows hot tapping/stoppling and hot tap/stopple welding shall be calculated by Project Engineer as per ASME Sec. VIII Div.1 and evaluated as per guidelines of API RP 2201 section 6.4 by Project Engineer.

ii. No piping containing steam shall be subject to Hot Tap/Stopple Welding if it has a pressure

greater than 10.5 Kg/cm2 or temperature greater than 260 0C.

iii. Water and nitrogen piping containing pressures under 14 Kg/cm2 shall have a minimum thickness of 5.1 millimetres.

iv. No piping containing nitrogen shall be subject to Hot Tap/Stopple Welding if it has a pressure greater than 14 Kg/cm2.

v. Piping that contains a gas shall have a calculated minimum flow velocity of 0.4 meters per second. Maximum flow velocity shall be limited by hot tap/ stopple machine design limit and approved by Project Engineer.

vi. Piping that contains a liquid shall have a calculated minimum flow velocity of 0.4 meters/second and a maximum flow velocity of 1.2 meters/second to avoid coupon dropped and carried over by liquid.

vii. Hot Tap/Stopple Welding shall not be performed on a piping bend or elbow.

4.8. Specific Limitations on Hot Tapping and Hot Tap Welding on Vessels/tanks

The following limitations shall apply to all vessels that are subject to have Hot Tap Welding performed on them:

i. No vessel will have Hot Tap Welding or a Hot Tap performed on it if it’s thickness is below the minimum nameplate thickness requirements.

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ii. Never pump in or out of vessels or agitate the contents of vessels/tanks while hot work is in progress. The agitator or switches shall be locked out in “OPEN” position. Close and lock out all valves on the product lines at the vessels/tanks.

iii. Avoid any procedures associated with operation of gas-blanketing valves or heater coil valves that would cause venting to occur.

iv. Vessels/Cone-roof Tanks.

a) Maintain at least 1 meter of liquid head above the hot work area when welding or similar hot work is being done. A tape gauge of the vessel/tank contents shall be made.

v. Floating-roof Tanks.

a) Welding may be performed at any point on the outside of the tank shell at least three feet below the liquid level and below the bottom of the roof seal shoe or envelope.

b) Unless the tank is emptied, isolated and made vapor free, never perform welding or similar hot work on the floating roof, on the sleeves of the roof legs, between primary and secondary seals, on pontoon hatches, or anywhere on the floating roof.

4.9. Hot Tapping/Stoppling Through a Bolt-on Fitting

i. Only qualified personnel who are thoroughly knowledgeable of the manufacturer’s recommendations and procedures shall attempt this procedure.

ii. The piping content shall not have any reaction with the sealing compound used to seal the clamp to the piping.

iii. Bolt-on Hot Tap fittings shall only be used when the option of welding for the hot tap fitting is not available. Bolt –on fitting is an option in cases where it is not possible to weld the hot tap fitting. Once a bolt-on fitting has been installed it cannot be replaced with a weld-on fitting until the line has been shutdown and de-inventoried as in a shutdown/turnaround scenario.

4.10. Testing of the Finished Hot Tap/Stopple Weld and the Attached Valve Prior to Cutting the Coupon:

i. Each valve used for Hot Tap/Stoppling is to be subjected to a high-pressure closure test per API 598 prior to the fit-up to the attachment fitting. This valve is to have no leakage. It shall be checked for appropriate metallurgy and trim.

ii. The full-opening valve with the same piping class as the point of installation, shall be attached to the finished welded attachment.

iii. The valve and the finished Hot Tap/Stopple weld shall be pressure tested as follows:

a) For non-category D fluids, as defined below, where the fitting is left in place making it a permanent part of the piping system, the test pressure will be the original hydrostatic test pressure.

b) For category D fluids, either the original hydrostatic test pressure or 1.1 times the current operating pressure can be used.

c) If the fitting is not to be permanent or employed in future service, then per API 2201 the test pressure shall be 1.1 times the current operating pressure.

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NOTE 2

Category D media:

Air

Inert gas

Water

Steam of 3.5 Kg/cm2 or less

Other non-flammable non-toxic fluids (lube oil, glycol, etc.) and subject to the following conditions:

○ Design pressure of 10.5 Kg/cm2 or less

○ Design temperature between -29ºC and 185ºC

iv. The Project Engineer shall compute an external pressure calculation to ensure that the pressure test of 1.1 times the maximum allowable working pressure will not collapse the piping under test. Refer to the latest edition of ASME Section VIII, Division 1, (Thickness of Shells and Tubes under External Pressure), for the appropriate formula when computing this pressure. This pressure test will be performed before the Hot Tap machine is attached to the valve.

v. Test the finished hot tap branch weld hydrostatically (before welding the reinforcing pad, if it is used) for sufficient time of minimum 1 hour to inspect for leaks, if below 95ºC. While if above 95ºC, use nitrogen or air test and hold for sufficient time to monitor the pressure gauge for leaks.

vi. If a reinforcing pad is used and the temperature is below 95ºC, a 0.7Kg/Cm2 (10 psig) pneumatic test through its peephole with leak detection by a soap and water solution. If above 95ºC, hold 0.7Kg/Cm2 (10 psig) pneumatic test for sufficient time to monitor the pressure gauge for leaks.

vii. Prior to making the cut, additional testing such as radiograph, dye penetrate or magnetic particle may be carried out at the discretion of ERG Plant Inspector and will be noted in the “Repair Alteration Travel Sheet” (RAT). Such additional testing will not be relied upon to replace hydrostatic or pneumatic testing.

viii. The pressure test shall be held and constantly attended for one hour so that pressure increases may be bled of through a quick opening valve.

5. RESPONSIBILITIES

5.1. Process Engineer

i. Provides mark-up P&IDs for the purpose of hot-tapping work.

ii. Verifies compatibility of consumable chemicals with process fluid in the pipeline.

iii. Ensures MOC approval process is complete before any work related hot tapping is started.

iv. Performs the calculated flow velocity present while welding is being performed.

5.2. Head of Project Engineering

i. Verifies the correctness of the work specifications of the Project Engineer.

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5.3. Project Engineer or Maintenance (as applicable)

i. Determines compatibility of the vessel or piping content with welding.

ii. Initiates the design.

iii. Engineering drafting, including the orientation of the attachment fitting.

iv. Initiates and follows the Hot Tap/Stopple Request until it has been approved or denied.

v. Involves all the disciplines in completion of the approval form.

vi. Determines proper material.

vii. Performs an external pressure calculation.

viii. Determines test pressure for attachment fitting and valve.

ix. Initiates the Work Order/Contract.

x. Submits proper documents to the Area Mechanical Planner.

xi. Provides applicable SDSs to Area Mechanical Planner.

xii. Orders material specified by the Project Engineer.

xiii. Receives material and ‘Mill Test Report’ from the vendor. (Warehouse/Procurement)

xiv. Creates a Work Package.

xv. Responsible for the overall duties on scheduling the work and planning the manpower and equipment needed for the job.

xvi. Co-ordinates with the Workshop Planner/Supervisor as necessary.

xvii. Obtains necessary approvals (IH) for any new chemicals coming on site, required for the hot tap/stopple work.

xviii. Ensure the hot tap valve to be used must be of adequate size and rating, be of proper metallurgy, and be a full opening valve.

xix. Reviews JSA along with his/her crew.

xx. Responsible for the safe implementation of the work at the work site whether a Contractor or Q-Chem performs the Hot Tapping/Stopple work.

xxi. Verifies the proper documentation is present at the work site.

xxii. Witnesses the post installation pressure test of the Hot Tap/Stopple machine.

xxiii. Keeps the Production Shift Supervisor advised of the status of the work while the work is being performed.

xxiv. Stops Hot Tap/Stopple work when the proper operating conditions cease to exist or at any time to continue the work would be considered unsafe.

xxv. Inspects the Hot Tap/Stopple Machine and the operation of that equipment to assure that the equipment is capable of performing the work. i.e., pressure rating and compatibility with the process.

xxvi. Required to follow all of the Hot Tap/Stopple Machine manufacturer’s recommendations for the use of the equipment at all times.

xxvii. Completes stopple travel measurement form.

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5.4. Safety Manager/HSE Superintendent

i. Initiates control of all safety requirements and regulations.

5.5. Plant Manager

i. Overall control of procedures, quality, and safety.

5.6. Production Area Superintendent/or Shift Supervisor Participate in the JSA

i. Reviews work scope for compliance’s to design, engineering, safety, and quality.

5.7. Safety Specialist

i. Follows work permit procedures and reviews work site for potential safety problems.

ii. Initiates or co-signs the proper permits.

iii. Participates in the “Job Safety Analysis”.

iv. Monitors all aspects of safety throughout the job.

5.8. ERG Plant Inspector/Lead Inspection Engineer

i. Inspects the pipe or vessel at the point where the Hot Tap/Stopple fitting is to be attached and carries out ultrasonic thickness survey. The results are to be documented properly and returned to the Mechanical Area Planner/Project Engineer/Design Engineer along with any recommendations and/or concerns.

ii. Inspects the received material for proper type and defects.

iii. Verifies the welding procedure and welder qualifications.

iv. Inspects the weld-out.

v. Valve has to be pressure tested and the cover has to be fitted to assure that it will work and fit properly.

vi. Ensure the requirements have been defined for weld inspection and for pressure testing.

vii. Verify the welded attachment and hot tapping machine are tested to assure they are in accordance with applicable codes before the cutting is started.

viii. Witnesses the Hot Tap/Stopple fitting and attached valve pressure test.

ix. Determines the type of pressure test.

5.9. Production Shift Supervisor

i. Responsible for assuring that required Operation’s personnel are prepared to implement emergency procedures.

ii. Assures the proper operating conditions exist before Hot Tap/Stopple Welding or Hot Tap/Stoppling is performed. Maintain the required flow during welding. Assures that valves having the potential to impact the volumetric flow during the Hot Tap/Stoppling Welding process are car sealed open and tagged with the “Do Not Operate or Use” tag.

iii. Stops Hot Tap/Stopple work when the proper operating conditions cease to exist at any time to continue the work would be considered unsafe.

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5.10. Fire Watch

i. Able to communicate effectively with personnel in the area.

ii. Watching for fires in all exposed areas.

iii. Knowing how to use the assigned fire suppression equipment.

iv. Knowing how and when to activate the facility fire alarm.

v. Activating the fire alarm first (when required).

vi. Trying to extinguish a fire only when obviously within the capacity of the equipment available (extinguisher or hose).

vii. Maintaining a watch for at least ½ hour after completion of welding, hot tap or other hot work until the area has been inspected and found to be free of leaks and ignition sources (fires, hot spots or smoldering materials).

5.11. DSR

i. Before starting the Hot Tap/Stopple work, DSR shall ensure that a JSA is conducted which addresses all issues. Required attendees are Contractor, Sub-Contractor, Operations, Maintenance, Safety and any other affected group.

ii. Before initiating the JSA, DSR shall review and approve the method statement including responsibilities, scope of work and all hazards associated with the job submitted by Contractor/Sub-Contractor.

iii. DSR schedules required training for Hot Tap/ Stopple work crew.

iv. Verifies Hot Tap/ Stopple work crew certification/qualifications.

v. Valve has been pressure tested and the cover fitted to assure that it will work and fit properly.

vi. All of the testing equipment on hand and in good working condition. Verifies that the welded attachment and hot tapping machine is tested and certified.

vii. Ensures the hot tap fittings, welded attachment and hot tapping machine are pressure tested.

5.12. Hot Tap/Stopple Machine Operator

i. Inspects the Hot Tap/Stopple Machine and the operation of that equipment to assure that the equipment is capable of performing the work. i.e., pressure rating and compatibility with the process.

ii. Required to follow all of the Hot Tap/Stopple Machine manufacturer’s recommendations for the use of the equipment at all times.

iii. Run the boring bar through the valve opening to ensure the cutter does not jam or drag.

iv. Ensure that the bleed-off valve will hold pressure and is not plugged.

v. Carefully calculate the travel distance of the cutter to ensure that the tap can be completed within the dimensional limits, that the cut will be stopped before the cutter or pilot drill touches the opposite side of the tapped pipe or equipment, and that the retrieved cut-out coupon can be retracted far enough to allow unimpeded closure of the tapping valve.

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vi. Ensure that precautions have been established for safe bleed off and disposal of material collected in the machine above the hot tap valve. It is Contractor Site Engineer’s responsibility.

vii. Ensure during installation the valve shall be centred on the nozzle flange or fixture. It is Contractor Site Engineer’s responsibility.

6. REFERENCES

6.1. API 2201, Safe Hot Taping Practices in the Petroleum and Petrochemical Industries.

6.2. API 598

6.3. ASME Section VIII Div. 1

6.4. Permit to Work Procedure – HSE-SAF-PRO-00-0006

7. ATTACHMENTS

7.1. Hot Tap/Stopple Approval Request Form - HSE-SAF-SFM-00-0024

7.2. Hot Tap/Stopple Sign-off Form - HSE-SAF-SFM-00-0025

7.3. Hot Tap/Stopple Measurement Form - HSE-SAF-SFM-00-0026

8. APPENDICES

8.1. Hot Tap/Stopple Work Sequence

8.1.1. Originator

i. Initiates SAP notification/TWR.

ii. Responsible for raising MOC and obtaining approval.

8.1.2. Project Engineer

i. Identifies the line and spot where the hot tap or stopple fitting is to be welded or bolted.

ii. Notifies the Equipment Inspector and requests an inspection.

8.1.3. ERG Plant Inspector

i. Inspects the line and records existing thickness, completes and signs the applicable spaces of the Hot Tap/Stopple Sign-off List.

ii. Submits the Hot Tap/Stopple Sign-off List to the Project Engineer.

iii. When the spot for the attachment fitting is not readily accessible the Inspector shall initiate a SAP notification calling for scaffolding to be erected.

iv. After the scaffolding has been erected, the Inspector shall have the line inspected and the inspection findings will be forwarded to the Project Engineer.

8.1.4. Project Engineer

i. Arranges a ‘Job Analysis’ and ‘Risk Assessment’ with Production/HSE/Maintenance.

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ii. Initiates and follows the Hot Tap/Stopple Request and all of its supporting documents until the request has been approved or denied.

iii. After the request has been approved, initiates a work order.

iv. Submits the proper documents to the Area Mechanical Planner.

8.1.5. Job Planner/Project Engineer

i. Orders material specified by Project Engineer.

ii. Receives material and the proper material documentation from the vendor.

iii. Creates a Work Package.

iv. Notifies the QC Inspector when the material arrives.

v. Submits the Work Package to the QC Inspector.


i. Inspects the received material for proper type and defects.

ii. Verifies the material documentation.

iii. Verifies the welding procedure and welder qualifications.

iv. Signs the Hot Tap/Stopple Sign-off List in the appropriate spaces after the material pass the inspection.


i. Notifies and coordinates the work with the Operations Shift Supervisor and the Maintenance Mechanical Engineer.

ii. Schedules the needed manpower and equipment to be used for Hot Tap/Stopple welding or Hot Tap/Stopple bolting.

iii. Submits the Work Package to the Maintenance Mechanical Engineer.

8.1.8. Maintenance/Technical Mechanical Engineer assigned

i. Notifies the Operations Shift Supervisor of the intended work prior to the commencement of the work.

ii. Reviews the appropriate SDSs with field team with respect to the product contained in the line which is to be Hot Tap/Stopple welded.

iii. Verifies the proper job information is available at the job site.

iv. Arranges for access to the location where inspection and work will be carried out.

v. Produces the appropriate SDSs for a review by the Welder performing the Hot Tap/Stopple Welding.

vi. Notifies the Area Safety Specialist of the work to be performed.

8.1.9. Welder

i. Carries out welding as per the approved WPS. Signs the Hot Tap/Stopple Sign-off List in the appropriate space.

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8.1.10. Area Safety Specialist

i. Reviews the work site for potential safety problems.

8.1.11. Operations Shift Supervisor

i. Signs the Hot Tap/Stopple Sign-off List at the appropriate space, indicating the proper operational conditions exist to perform the Hot Tap/Stopple Welding.


i. Verifies that the operational conditions are satisfactory for performing Hot Tap/Stopple Welding.

ii. Communicates safety and work instructions to the individuals performing the work.

iii. Stops the work when the fit-up is completed.

iv. Notifies the ERG Plant Inspector for the fit-up completion.


i. Inspects and approves the fit-up.

ii. Signs the Hot Tap/Stopple Sign-off List in the appropriate space after the fit-up passes inspection.


i. Resumes the work.

ii. Notifies the QC Inspector of the work completion.


i. Inspects the weld-out.

ii. Witnesses the pressure test of the Hot Tap/Stopple fitting and block valve.

iii. Signs the Hot Tap/Stopple Sign-off List in the appropriate space.

8.1.16. Maintenance/Technical Mechanical Engineer

i. Notifies the Operations Team Leader of the completion of work on that portion of the Hot Tap/Stopple.

ii. Returns the Work Package to the Area Mechanical Planner.


i. Contacts the Hot Tap/Stopple Contractor and plans the time and date of the Hot Tap/Stopple.

ii. The Hot Tap/Stopple Contractor is told the Maintenance/Technical Mechanical Engineer’s name.

iii. Informs the Operations Shift Supervisor and the Maintenance/Technical Mechanical Engineer of the expected time and date of arrival of the Hot Tap/Stopple Machine Operator.

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iv. Schedules needed equipment and manpower to be used for the installation of the Hot Tap/Stopple Machine.

8.1.18. Hot Tap Machine Operator

i. Reports to and signs-in in the Unit Control Room.

ii. Notifies the Maintenance/Technical Mechanical Engineer of his/her arrival.


i. Receives the Work Package.

ii. Informs the Operations Shift Supervisor, of the Hot Tap/Stopple Machine Operator’s arrival.

iii. Makes appropriate SDSs available to the Hot Tap/Stopple Machine Operator.

iv. Notifies the Area Safety Specialist of the work.

8.1.20. Hot Tap/Stopple Machine Operator

i. Reads the appropriate SDSs.

ii. Signs the Hot Tap/Stopple Sign-off List in the appropriate space.

iii. Inspects the Hot Tap/Stopple Machine and the Hot Tap/Stopple Machine operation.

iv. Signs the Hot Tap/Stopple Sign-off List in the appropriate space.

v. Prepares measurement form.

8.1.21. Area Safety Specialist

i. Reviews the work site for potential safety problems.

ii. Issues or co-signs the needed safety permits.


i. Communicates safety and work instructions to the individuals performing the work.

ii. Supervises the individuals assisting the Hot Tap/Stopple Machine Operator with the installation of the Hot Tap/Stopple machine.

8.1.23. Maintenance/Technical Mechanical Engineer and Hot Tap/Stopple Machine Operator

i. Witness the pressure test after the Hot Tap/Stopple machine has been installed.

ii. Both individuals sign the Hot Tap/Stopple Sign-off List in the appropriate space verifies that the coupon catcher is on the pilot drill bit.

8.1.24. Operations Shift Supervisor

i. Verifies that the correct operating condition exist for the Hot Tap/Stopple work.

ii. Signs the Hot Tap/Stopple Sign-off List at the appropriate space.

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i. Verifies the correct operating condition exist for the Hot Tap/Stopple work.

8.1.26. Hot Tap/Stopple Machine Operator

i. Performs the Hot Tap/Stopple.

ii. Retrieves the coupon.

iii. Gives the coupon to the Maintenance/Technical Mechanical Engineer.


i. Receives and inspects the coupon for completeness.

ii. Signs the Hot Tap/Stopple Sign-off List at the appropriate space.

iii. When Stoppling, supervises the individuals performing work downstream of the stopple.

iv. After completion of the Hot Tap/Stopple work, supervises the individuals assisting the Hot Tap/Stopple Machine Operator to remove the Hot Tap/Stopple machine.

v. Signs the completed Work Order.

vi. Informs the Operations Shift Supervisor of the work completion.

vii. Returns the Work Package to the Area Mechanical Planner/Project Engineer.


i. Verifies that all the required signatures are present and that the work is completed.

ii. Sends the completed Work Package to RIM/DCC Group for record keeping.

iii. Ensures necessary engineering documents uploaded in ECM as per MOC process.

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8.2. Appendix - II: Typical Hot Tap Activity Flow

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8.3. Appendix III – Example Process to Review whether Hot Tapping is Appropriate

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9. REVISION HISTORY

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

3 01-Feb-15

Change Category: Type-1

The following contents shall not have the Hot Tap/Stopple Welding performed on them without an approval: Vapour/air or vapour/oxygen mixtures, Compressed air Systems, Combustibles, Temperature-Sensitive, Chemically reactive materials, Rotating Equipments. (4.4.(iv) to (vii)).

Topic on ‘Hot Tap Location included.(4.5)

Responsibility of ERG Plant Inspector to pressure test valve and ensure the welded attachment and hot tapping machine are tested to assure they are in accordance with applicable codes before the cutting is started. (5.8. (v – viii)).

Responsibilities of DSR and Hot Tap/Stopple Machine Operator are added (5.11 & 5.12).

Muhammad F Khan

Carl Benson Anthony D

Dugat Arif Javed

Choondassery Umesh

Ahmed J Al-Subeay

Hesham Y El-Zeini

Abdul W Sheikh Mazhar Sajjad

Ketan S Kulkarni

Gary L Piana Chad A

Jennings Carl Poldrack

Roehl Bartolome

Saleh Abdulla Abdulla S Al-

Khulaifi Kevin C Kabell

Ali Al-Marri Anuraag B

Malve

2 27-Nov-13 Periodic Revision. Carl Benson Review Team Carl Poldrack

1.2 15 Nov. 11

Scheduled Review. No notable technical changes identified. Included Technical Engineer with Maintenance Engineer roles and responsibilities.

Scott Sutherland

Review Team Carl Poldrack

1.1 17 Feb 08 Minor Change: Updated Designation changes at Q1 and incorporated RLOC positions.

Imran Malik

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